Apparatus for opening and unloading cartons



Feb. 16, 1960 M. CANDIDO, JR 2,925,185

APPARATUS FOR OPENING AND UNLOADING CARTONS Filed April 4, 1957 4 Sheets-Sheet l IN VEN TOR.

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ATTOHNEYJ Feb. 16, 1960 M. CANDIDO, JR 2,925,185

APPARATUS FOR OPENING AND UNLOADING CARTONS Filed April 4, 1957 4 Sheets-Sheet 2 ATTORNEYS Feb. 16, 1960 M. CANDIDO, JR APPARATUS FOR OPENING AND UNLOADING CARTONS Filed April 4, 1957 4 Sheets-Sheet 3 W m m m ATTOEIVEJG Feb. 16, 1960 M. CANDIDO, JR

APPARATUS FOR OPENING AND UNLOADING CARTONS Filed April 4, 19s7 4 Sheets-Sheet 4 IN VEN TQR. M idmel camiuiczjl". BY 6m/1 A TTORNE K5 United States Patent APPARATUS FOR OPENING AND UNLOADING CARTONS Michael Candide, Jr., Crestwood, N.Y., assignor to Chas. Pfizer & Co., Inc., New York, N.Y., a corporation of Delaware Application April 4, 1957, Serial No. 650,622 11 Claims. (Cl. 214-304) This invention relates to an apparatus for opening and unloading inverted cartons filled with articles, and more particularly relates to an apparatus of the aforementioned type in which the opening and unloading operations are automatically performed as the cartons are in transit upon a moving conveyor.

Various devices have been proposed for opening and emptying inverted cartons filled with articles such as small containers or bottles. The term inverted is herein used to designate cartons Whose bottoms are opened to unload them rather than their tops which is considered more conventional. Representative examples of such a device are disclosed, for example, in U.S. Letters Patent No. 2,323,852. There are several demanding problems which must be satisfied by a device of this type. First, these devices may include a number of separate conveyors upon which various operations are successively performed such as opening inner and outer pairs of flaps at the bottoms of the cartons. It is dithcult to synchronize these conveyors so that a smooth flow of cartons is channelled from one to the other. Another problem which is difiicult to solve is retention of the articles within the carton until it reaches an appointed dropping position during and after the time that the'inner flaps at'the bottom of the carton" are opened. This problem is particularly accentuated when the articles arecomparativelysmall and light.

An object of this invention is to provide an apparatus for opening and unloading inverted cartons which provides a smooth and continuous flow of cartons through successive stages Another object is to provide an apparatus of the aforementioned type which includes a device for retaining the articles within the cartons duringand after the timethat the inner fiaps at the bottom of the cartons are opened and until the cartons arrive at a predetermined dropping position.

In accordance with this invention, a first conveyor is disposed substantially perpendicular to and intersecting the path of .a second conveyor. Flap engaging means are disposed adjacent these conveyors for respectively opening the outer and inner flaps at the bottom of the inverted cartons as they pass along the conveyors with the separation between the flaps to be opened disposed parallel to the direction of movement of the cartons. A positive drive means is provided for successively carrying cartons through the second conveyor, and the first conveyor includes a, slidable drive means. This 'slidable drive means iscapable of slipping relative to cartons passing through the first conveyor to permit cartons to be unloaded and transferred through it independent of the operating phase of the second. conveyor. An apertured retaining means is incorporated in the second conveyor for maintaining articles inserted within the cartons until they reach a predetermined aperture or dropping position. This retaining'. means includes, for example, three parallel tracks. .The central track is initially narrow enough to lie between the space between the inner flaps at the bottom of the cartons, and it then widens to gradually open the inner flaps and support the articles to prevent them from prematurely dropping from the cartons.

Novel features and advantages of the present invention will become apparent 'to one skilled in the art from a reading of the following description in conjunction with the accompanying drawings wherein similar reference characters refer to similar parts and in which:

Fig. 1 is a perspective view of one embodiment of this invention;

Fig. 2 is a perspective view of initial portions of the embodiment shown in Fig. 1;

Fig. 3 is a perspective view of the embodiment shown in Fig. 1, particularly illustrating final operating stages;

Fig. 4 is a cross-sectional view taken through Figs. 3

and 6 along the line 4-4 and looking in the direction of I the arrows;

Fig. 5 is a schematic diagram in elevation of a final phase of operation of the embodiment shown in Figs. l-3;

Fig. 6 is a cross-sectional view taken through Fig. 5 along the line 6-6 and looking in the direction of the arrows;

Figs. 7-9 are cross-sectional views taken respectively through Fig. 6 along the lines 77, 8--8 and 99 and looking in the direction of the arrows.

Fig. 1 shows an apparatus 10 for opening and unloading inverted cartons l2 filled with articles 14 which are, for example, small bottles of glass or a less dense material such as polyethylene plastic. Cartons 12, for example, include dividing strips 16 of cardboard, for example, which partition cartons 12 into compartments 18, for example, twelve in number. Cartons 12 are designated as inverted because the flaps at their bottom are opened to discharge their contents instead of the normal unloading procedure in which cartons are opened from the top to take out contents. The outer flaps 20 at the bottoms of the cartons are opened first and the inner flaps 22 at the bottoms of the cartons are then opened to discharge the contents.

In Fig. 1 a carton 12 is shown at the lower right in the position which it is placed immediately prior to being inserted in the first conveyor stage 24 where the outer flaps 20 at the bottom of cartons 12 are opened. Cartons 12 pass through first conveyor or first stage 24 with the separation 26 between the flaps 20 disposed parallel to the direction of movement of the'cartons through conveyor 24.

After passage through first conveyor 24, cartons 12 are abstracted by intersecting second conveyor 28 whereon the inner flaps 22 at the bottoms of cartons 12 are opened to discharge bottles 14 to a third conveyor 30 which carries them away to processing apparatus, for example (not shown). Cartons 12 are carried off by second conveyor 28 to be disposed of or reused. Second conveyor 28 is shielded by a safety cover or guard 29 which prevents injury to operating personnel.

Details of first conveyor 24. are illustrated in Figs. 1, 2 and 3. First conveyor 24 includes a slidable drive means 32 for transferring cartons 12 through conveyor 24. Slidable drive means 32 is, for example, an endless flexible conveyor belt 32 which forms one of the side walls of conveyor stage 24. An anti-friction guide means 34 forms the other side wall of conveyor 24. Anti-friction guide means 34 is, for example, an array of rolls 36 mounted on ball bearings. Belt 32 and rollers 36 are spaced apart a distance substantially equal to the width of cartons 12. The free distance there between may be slightly less than the width of the cartOns because flexible belt 32 can be deformed to hug the sides of 'thecarton." Belt 32 propels cartons 12 quit-e forcefully but can slip relative to the cartons, to. permit.

cartons 12 to be stored in first stage or first conveyor 24 in readiness for abstraction by second conveyor 28. This permits cartons 12 to be loaded andhel'd inv readiness; in first conveyor 24 independent of the operating phase of secondconveyor 28;.

The entrance to first conveyor 24 is formed; by a horizontal baseplate 38 including a higher level 40 and a lower level 42 connected by a sloping offset section 44. A continuation 46. of means for mounting rollers 36 extends parallel to. offset section 44 and includes a lower section or flange 48 sloped and disposed opposite to olfset section 44 toform a slope-walled depression for receiving the bottoms of carton 12 and allowing outer flaps 20' at the bottoms of the cartons to start to open when the cartons are loaded or inserted upon the depression in the direction indicated.v

A first flap engaging means 50 is disposed adjacent first conveyor 24 for engaging and opening outer flaps 20 as the cartons move past it. Flap, engaging means 50 is, for example, a V-shaped plough having curved front edges.

After being moved past plough 50, cartons 12 are carried along a horizontal endless belt 52 which intersects the path of movement of second conveyor or stage 28. Second conveyor 28 intersectsthepath of movement of first conveyor 24, for example, at right angles. This provides a smooth mode of transfer from first conveyor 24 to. second conveyor 28 and also helps conservevaluable fioor space.

A pair of alternately operating carton restraining means 54 (see Fig. 2) are. disposed along first conveyor 24 spaced from each other a distance which causes them to contact successive cartons 12 passing along conveyor 24. Each restraining means 54 includes, for example, plunger 56. reciprocally operated by pneumatic cylinders 58, for example, which are alternately driven backward and forward by a conventional control apparatus (not shown). The cycle. of movement of plunger 56 is governed only by the time required for positively driving second couveyor 28 to abstract a carton 12 and move it completely free of horidontal conveyor belt 52 of first conveyor 24.

Plungers 56, include, for example, hemispherical heads made of a material having frictional properties such as rubber. First plunger 56, furthest away from second conveyor 28, arrests'or restrains a carton 12 as, the preceding carton is being released by second plunger 56.nearestv conveyor 28. When the released carton is clear of second plunger 56 nearest conveyor 28, first plunger 56' releases its carton which is restrained by forward movement of the second plunger 56 which holds it in readiness for release to second conveyor 28. Cartons are, therefore, fed one at a time from one restraining means 54 to the other and one at a time to second conveyor 28.

A guide rail 60. is disposed above and parallel to the path. of movement of first conveyor 24 for maintaining cartons 12 in a predeterminedvertical orientation as they pass through first conveyor- 24. The entrance portion of rail 60 is. formed by the web of a smooth channel 62 Whi h extends above the path of movement ofcartons.

through slidable drive means 32. However, the portion.

64 of rail. 68 adjacent horizontal belt 52 and restraining means 54 includes anti-friction, means 66, for example,

' ball bearing rollers mounted within, the legs, extending downwardly trom the web of channel '68. Rollers 66 prevent cartons 12 trom being thrown outof positionand snagged by. the upsetting action of restraining means 54.

Referring to Figs. 1-3 cartons 12 are delivered from free of horizontal conveyor belt 52 of first conveyor 24. tom flaps 20 spread in a horizontal position by the action of plough 58. Second conveyor 28 includes a positive drive means 69, for example, a sprocket chain; drive 70 including spaced angles or lugs 72. A carton 12 is picked up. by each lug 7.2, as it intersects thev pathv of travel, of

fint c a exat 3. Qantas we e fi e -abs mol st. ng.

second. conveyor 28 with the separation. 74. between the bottom inner flaps 22 parallel to the direction of their movement along second conveyor 28.

Second conveyor 28 includes an apertured retaining means 76 for maintaining articles or bottoms 14 inserted within cartons 12 until. the cartons reach aperture or dropping station. 78. where the articles, are delivered or dropped upon third conveyor 30. Details of retaining means 76 are shown in Figs. 5 through 9. Retaining means76, includes 3, parallel tracks 80, 82, and84. Cen. tral track 82 is initially narrow as shown at 86. Section 86 is narrow enough to lie within the space or; separation 74 formedbetween the bottom. inner flaps. 22. Outer tracks 80 are spaced from central track 86 a distance sulficient to support the outer bottom edges of cartons 12 and to permit the bottom inner flaps 22 to drop below the level of initial central track section 86 as shown in Fig. 7. Meanwhile, tracks 84. and 86 maintain outer flaps 20. opened and extending to the front and rear of the path of. movement of cartons 12. along second conveyor 28,.

Central track 82 gradually widens at section 88 to approach the inner edges of outer tracks 80, and 84.. Grad: ually widening center; track secti'on88 enters. above dropping inner flaps 2,2 and maintains articles 14 inserted. within cartons 12. as inner, flaps 22 are diverted. below outer tracks 80 and. 84by widening central track section 88 (see Fig. 8).

Outer tracks 80 and 84 then abruptly terminate at 90 and 92 respectively to permit inner flaps 22 to freely drop as they pass along both sides of the full width of central track 82. After inner flaps 22 have completely moved free of ends 90 and 92 of outer tracks80 and 84, they are contacted by the leading edges of V-shaped fins 94 and 96 which sweep back in a V-shaped array which ismounted, for example, upon the-bottom of central track section 82. Swept back fins 94 and 96 enter under inner flaps 22 to force them up and out to the substantially horizontal position shown. in Fig. 9.

After cartons 12 move past fins 94 and 96, flaps 22 encounter a diverter means 98 which guides them into a pair of slots 100 and 102 formed between parallel pairs of vertically spaced inclined rails 104. Diverter means 98 is made, for example, in the form of a V-shaped plough including upwardly curved or rolled front edges or surfaces 106-and rear surfaces 108 which slope upwardly to join the entrances 110- to inclined slots 100 and 102. Lower rails 104 smoothly join rear surfaces 108 of diverter 98 to permit laterally spread flaps 22 to be smoothly guided int-o entrances 110. Frontedges 112 of upper ralls 104 are upwardly curved to cooperate in guiding inner flaps 22 into inclined slots 100 and 102. Diverter 98 is formed, for example, of a continuous sheet whose front edge is rolled up and over and whose rear edges or surfacesare upwardly sloped continuations of' the upwardly rolled front edges 106.

All of the time, that cartons 12 move along retaining means 76, contents or articles 18 are maintained inserted in cartons 12 by the widened. central track section 82. A continuation 114 of central track'section 82 extends a, shortdistance. over third conveyor, 30 up to the apere ture or. predetermined dropping position 78. --As thecartons moveup inclined rails 104 they are gradually movedup and away from. articles or bottles 14 which are deposited successively upon third conveyor 30'after the cartons move past. aperture or dropping position 78. Bottles 14 are, therefore, smoothly dropped from plate 114 onto the. surface, of conveyor 30whose speed iscoordinated with the speed of sprocket chain 70 and lugs 72. to cause, cartons12 and dropped bottles 14 to move alongside each, other without interference respectively upon inclined tracks 104 and third conveyor 30.

Pairs of rails 104' are spaced. from each other, for example, ahorizontal distance slightly less than the free: w de t-"sauna .1. parat ng w itin s: .6. ar he e.-

fore, wedged in;place between the walls of carton 12 and maintained in place as bottles 14 are dropped upon third conveyor 30.' Cartons 12 and separating partitions 16 are, therefore, moved ofi to another location as bottles 14 are discharged bythird conveyor 30, for example, to an accumulator table 116 which stores them in readiness to be abstracted by another conveyor (not shown) which carries them away to other processing apparatus such as filling or labelling machinery.

Summary of operation Cartons 12 are loaded or inserted upon first conveyor 24 with the separation 26 between bottom flaps 20 disposed parallel to their direction of movement through first conveyor 24. Any fastening such as tape across outer bottom flaps 20 has been either omitted or slit. Cartons 12 then traverse slidable drive means or belt 32. As they move past plough 50, the outer bottom flaps 20 are engaged and laterally opened- The slidable drive applied to' the sides of the cartons leaves the bottoms free fo'r efficient manipulation. After flaps 20 are opened by plough 50, cartons 12 are carried upon horizontal conveyor 'belt 52 past restraini'ngmeans 54 which alternately an'd successively arrest theniand feed them one at a time to the second conveyor 28. Cartons 12 may be fed almost as quickly as desired to first conveyor 24 because the slippage between conveyor belt 32 and cartons 12 permits cartons to be stored in readiness upon first conveyor 24 to be fed at a predetermined rate by restraining means 54 to second conveyor 28.

The positive drive means 69 of second conveyor 28 including lugs 72 moves cartons 12 along second-conveyor 28 in a direction parallel to separation 74 between bottom inner flaps 22. As cartons 12 move across retaining means 76 to the dropping out position or aperture 78, parallel track 82 is initially narrow enough at 86 to lie between inner flaps 22 and then widens at 88 to a substantial width which is inserted over dropped inner fiaps 22 which are partially supported by outer rails 80 and 84. When central track 82 has widened to its full width to support bottles 14 within inverted carton 12, outer tracks 80 and 84 respectively terminate at 90 and 92 to permit inner flaps 22 to be raised to a substantially horizontal position by swept back fins 94 and 96.

Diverter 98 then guides flaps 22 into inclined slots 100 and 102 provided by pairs of vertically spaced and inclined rails 104. As the cartons move up inclined slots 100 and 102, bottles 14 slide to the edge of drop out plate 114 where they smoothly drop onto third conveyor 30 when they reach aperture or dropping position 78. Bottles 14 are smoothly urged over edge 115 of plate 114 by the forward motion of a partition 16 or a wall of carton 12 depending upon which portion of carton 12 is in back of a particular bottle. The speeds of third conveyor belt 30 and positive drive means 69 of second conveyor 28 are coordinated to prevent interference between rising cartons 12 and articles 14 as they move off to their separate destinations. Dividing partitions 16 are maintained within cartons 12 by the wedging action between pairs of inclined rails 104 which are horizontally spaced apart a distance slightly less than the width of cartons 12.

What is claimed is:

1. An apparatus for opening the bottom flaps of inverted cartons filled with articles and for unloading said articles, said apparatus comprising a first conveyor including a pair of parallel side walls spaced apart a distance substantially equal to the width of said cartons, an endless conveyor belt forming one of said side walls, an anti-friction guide means forming the other of said side walls, said endless conveyor belt being actuated to move in a direction which causes its surface adjacent said anti-friction guide means to move in the desired direction of movement of said cartons, first fiap engaging means disposed adjacent said first conveyor for opening the outer flaps at the bottom of said cartons as said cartons move with the separation between said actual flaps disposed parallel to the direction of carton movement, a second conveyor, second flap engaging means disposed adjacent said second conveyor for opening the inner flaps at the bottom of said cartons as said cartons move with the separation between said inner flaps disposed parallel to the direction of movement of said cartons, said first conveyor being disposed substantially perpendicular to and intersecting the path of said second conveyor, said second conveyor including positive drive means for successively carrying said cartons therethrough, said first conveyor being capable of slipping relative to cartons passing therethrough to permit cartons to be loaded and transported therethrough independent of the operating phase of said second conveyor, said second conveyor including an apertured retaining means for maintaining said articles inserted within said cartons until said cartons reach said aperture, said retaining means including three parallel tracks, the central track initially being narrow enough to lie between the space between said inner flaps at the bottom of said cartons, said outer tracks being spaced fromsaid central track a distance sufiicient to support the outer edges of said cartons and to permit said inner flaps to drop below said central track, all of said tracks maintaining said outer flaps opened and extending to the front and rear of the path of movement of said cartons as they are moved along said second conveyor, and a third conveyor disposed beneath said aperture for carrying away said articles.

2. An apparatus as set forth in claim 1 wherein the entrance to said first conveyor is comprised of a horizontal base plate including higher and lower levels connected by a sloping offset section, a continuation of said side wall including said anti-friction guide means extending parallel to said offset section, and said continuation including a lower section sloped and disposed opposite to said offset section to form a slope-walled depression for receiving the bottoms of said cartons and allowing said outer flaps to start to open when said cartons are loaded therein with the separation between said outer flaps disposed parallel to said side walls.

3. An apparatus as set forth in claim 1 wherein said central track gadually widens to approach the inner edges of said outer tracks, said gradually widening center track entering above said dropping inner flaps and maintaining said articles inserted within said cartons as said inner fiaps are diverted below said outer tracks by said gradually widening central track.

4. An apparatus as set forth in claim 3 wherein said outer tracks terminate to permit said inner flaps to freely drop when said center track has widened sufiiciently to support the contents of said cartons.

5. An apparatus as set forth in claim 4 wherein V- shaped fins extend and sweep back from said widened center track, and said swept back fins enter under said freely dropped inner flaps to force them up and out into a horizontal position after said inner flaps have passed the ends of said outer tracks.

6. An apparatus as set forth in claim 5 wherein two parallel pairs of vertically spaced rails are horizontally spaced from each other a distance equal to the width of said cartons, said pairs of rails being disposed in the path of movement of said horizontally extending inner flaps of said cartons, and diverting means being connected to the entrance to said bottom rails of said pairs of rails for guiding said horizontally extending flaps into the slots formed between said pairs of rails.

7. An apparatus as set forth in claim 6 wherein said diverter means is comprised of a V-shaped plough including upwardly curved front edges and rear surfaces which slope upwardly to join the entrance to said slots.

8. An apparatus as set forth in claim 7 wherein said diverter means is comprised of a continuous sheet whose mamas an; upwardly sloped continuation of the, lower portion of said front edge.

9. An apparatus as set forth in claim 6 wherein said cartons include partitioning elements andsaid two pairs of rails are horizontally spaced apart a distance slightly less than the free width of said cartons to wedge said partitions between the walls of said cartons and maintain them in place as said" articles are dropped.

10; A retaining device for maintaining articlesrihsertted within inverted cartons in transit upon a conveyor comprising a plate which is wider than the width. of said cartons, three parallel tracks extending backward from said plate, the central trackv initially being narrow enough to lie within the space between said inner flaps at the bottom of said' cartons, said outer tracks being spaced from said central track a distance. sufiicient to support the outer edges ofisaid; cartons and to. permit said inner flaps to drop below said central track, and. all of said tracks maintaining. said. outer flaps opened and extending to the front and rear. of. the path of movement of said cartons as. they are moved along saidj con; y r sa tra ack sra uellx widenin 9 pr sed! 8; a a he inne dges, of sa d? enter iraska'saidi stadlxa z w enihg n r l track nte i a ove a d; dr p s flaps] nd m n a nin i r icles; ins rted, w thm s id cartons as said inner flaps arerdi erted-helow said outer c y d g ual y w ening; inner r ck; sa intr a ks erm a in o. pe m t s e fll 12 to re ly drop when said central track has widened, sufijcientl'y' to support the contents of said cartons V-shaped' fins etc-r tending and sweeping back from said widening central track, and said sweeping-back fins entering under said freely dropped inner flaps to foreerthem. up and. out into a horizontal position after said inner flaps havev passed the ends of said outer tracks. a

1 1.v A device as set forth in; claim 1Q?whereinsaid widened. center track abruptly terminates tolpcrrni tsaid articles to. drop fr ee1y. from saidcartons 7 References (Zited in: the file" of this patent I U I E!) TATES: PMENT 2,3 2 851 2,415,198,- 2,684,799 1.54. 114

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 2,925,185

February 16, 1960 Michael Candido, Jr.

and that the said Letters read as corrected below.

Column 3 line 42 for "horidontal" read horizontal line 69 strike out "fre onveyor belt 52 of first conveyor 24. and insert instead first conveyor 24 to second conveyor 28 with Signed and sealed this 16th day of August 1960.

(SEAL) Attest:

KARL H. AXLINE ROBERT C. WATSON Attesting Officer Commissioner of Patents 

